Body - Liftgate Paint Cracked In Hinge Area
Bulletin No: 09-010/10Last Issued: 02/15/2010
Subject
LIFTGATE HINGE PAINT CRACKED
APPLICABLE MODEL(S)/VINS
2006 Mazda5 vehicles with VINS lower than JM1 ******** 132688 (produced before July 25, 2006)
DESCRIPTION
On some vehicles, a crack may appear on the liftgate hinge painted area. This is caused by a crack on the lift-gate outer panel causing the paint to crack as well. The shape of the liftgate hinge outer panel (hinge) has been changed in order to increase the thickness of the area.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
NOTE:
This repair procedure requires a specific adhesive. Please use ThreeBond Repair Kit xxx.
2. Check the seriousness of the crack (A) on the liftgate hinge. If the crack situation falls under a, b, c, or d, it is not possible to repair the crack and the liftgate panel must be replaced.
a. The crack on the outer panel is more than 3 mm wide.
NOTE:
It is like the outer panel is partially missing and the area where adhesive needs to be applied is too wide.
b. The difference between a cracked panel is more than 3 mm.
NOTE:
This happens because the outer panel is partially deformed and the groove where the glue goes is deformed as well.
c. The deformation of the cracked panel extends to the inner panel (A) sealing where the weatherstrip contacts.
d. The crack on the outer panel extends and reaches to where the glass is installed (B).
3. If the affected area cannot be sanded or re-painted properly because of the seriousness of the crack, then remove the liftgate from the vehicle and install a new one. Refer to MS3 online instructions or Workshop manual section 01-12 LIFTGATE REMOVAL/INSTALLATION.
NOTE:
When the liftgate is removed, pay special attention when handling it and avoid putting weight on the glass surface. Place the liftgate on a blanket.
4. Using an electric cutter or equivalent tool, remove the cracked location (A) as shown in the following illustration.
NOTE:
Make sure the removed width is less than 1.0 mm (B).
5. Remove the glue residue, water, grease, and other debris from the area around the crack.
6. Using the "Surface Wipes" in the Repair Kit, clean the "groove" where the glue is to be applied.
NOTE:
^ Be sure to wear mask, glove, glasses, and other proper protection.
^ Use the glue in a well ventilation area or outside.
^ In some cases, the glue may generate heat or emit gas. DO NOT touch with naked fingers or inhale the gas directly.
^ When applying the glue (A) to the panel (B), make sure the thickness of the applied glue is 0.5- 3.0 mm. This is because the glue will shrink when it dries, and some thickness is needed to ensure there is enough.
^ Be careful not to apply too much, otherwise it will start dripping or take too long to polish.
7. After the glue dries, polish it to make it flush.
NOTE:
^ The time required to dry will vary depending on the amount of glue applied (length and depth of the location to be repaired.)
^ Let it dry for about 2 hours in a temperature of 20 °C (68 °F) or higher. When the glue is no longer sticky, polish the glue.
^ If the temperature is lower than 20 °C (68 °F), use an infrared heat lamp or heater to help it dry.
8. Apply putty (for bumper repair) over the glue.
NOTE:
The purpose of this putty is to fill in any remaining air bubbles in the glue.
9. Using sandpaper (# 300, # 600, and # 1000), sand the putty.
10. Refinish the required areas.
11. Verify repair.
PART(S) INFORMATION
NOTE:
Only the ThreeBond Repair Kit needs to be order the first time. Then after that, the Replacement Adhesive can be ordered.
WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
^ This repair will be covered under Mazda's New Vehicle Limited Warranty term. Additional diagnostic time cannot be claimed for this repair.